This paper presents the fabrication and machinability assessment of aluminum metal matrix composites (Al- MMC). Boron carbide (B4C) particles having average size of 37 μm is dispersed in 6061-T6 matrix alloy. The composite bar was fabricated through mechanical assisted stir casting method. Machining experiments based on Taguchi's L9 orthogonal array was conducted under dry condition using multi-layer coated carbide insert (TiN/Al203/TiCN/TiN). Machinability indices such as surface roughness (Ra, Rt and Rz) and cutting force (Fz) were considered as response measures. The results obtained from experiments were analyzed to predict the optimal machining conditions using Taguchi single objective approach. From the statistical analysis it was found that the feed rate is the most influencing factor for both surface roughness and cutting force followed by depth of cut. The developed mathematical model shows that the experimental and predicated results are very close to each other. Finally, the single optimal process parameter combination was found using weighted grey analysis (WGA) and the optimal results are verified through confirmation experiment. © 2006-2014 Asian Research Publishing Network (ARPN).